Multi-Layered Container

ABSTRACT

A multi-layered container for containing content adapted to be consumed. The multi-layered container includes a first sheet positioned at a bottom of the multi-layered container and adapted to contain a first content. A second sheet stacked on top of the first sheet and adapted to contain a second content. An adhesive is applied to edges of the first sheet except to at least one non-adhesive edge of the first sheet. The at least one non-adhesive edge of the first sheet enables the second sheet to be peeled off. An upper surface of the first sheet is exposed for the first content to be placed when the second sheet is peeled off from the first sheet.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 61/675,479 filed on Jul. 25, 2012, the complete disclosure of which, in its entirety, is herein incorporated by reference.

BACKGROUND

1. Technical Field

The embodiments herein generally relate to tableware, and, more particularly, to paper plates and containers.

2. Description of the Related Art

Disposable paper plates have been used for enjoying meals without having to wash and clean, as they are simply discarded after use. They are great for quick pick-up meals, snacks during the day, and almost essential for camping or picnicking. There is an extraordinary variety of disposable paper plates/containers available in the market, each type with its own merits. However, while convenient, disposable paper plates are generally wasteful because they are thrown away after a single use, while the plate may still be in good condition. They are generally constructed with thick composite paper in order to provide sufficient thickness and rigidity to contain any meal. Though only the top layer is typically spoiled by food, once used, the plate is entirely tossed away, with good and unused material gone to waste.

Paper/plastic/Styrofoam® plates eventually end up lying in landfills for decades or longer. Disposable paper plates/containers are usually inexpensive to manufacture, sold in bulk quantities, and not typically fragile. Conversely, reusable plastic plates are much more expensive to manufacture, they are sold in small sets (usually in sets of 4 or 8), and can be quite fragile. A pulp paper heavy-duty product creates a better quality of paper plate. It is good for serving hot food as it is heat and tear resistant. Hence, it is economical and cost efficient for a large group. Biodegradable and compostable plates are a good alternative and some types can be washed and reused, however, the overuse of soap and water is also wasteful and harmful to the environment. Accordingly, there remains a need for a container/plate that can be reused several times without wasting water, using dish soap, or filling up landfills.

SUMMARY

In view of the foregoing, an embodiment herein provides a multi-layered container for containing content adapted to be consumed, the multi-layered container comprising a first sheet positioned at a bottom of the multi-layered container and adapted to contain a first content; a second sheet stacked on top of the first sheet and adapted to contain a second content; and an adhesive that is applied to edges of the first sheet except to at least one non-adhesive edge of the first sheet, wherein the at least one non-adhesive edge of the first sheet enables the second sheet to be peeled off, and wherein when the second sheet is peeled off from the first sheet, an upper surface of the first sheet is exposed for the first content to be placed thereon. The thickness of the first sheet may be greater than a thickness of the second sheet. The multi-layered container may further comprise a third sheet that is stacked above the second sheet. The thickness of the third sheet may be equal to the thickness of the second sheet. The upper surfaces of the first sheet, the second sheet, and the third sheet may be coated with a coatable substance. A lower surface of the first sheet may be coated with the coatable substance. The first sheet, the second sheet, and the third sheet may comprise any of biodegradable and compostable materials.

Another aspect of the embodiments herein provides a multi-layered plate comprising a plurality of stacked sheets for containing content for consumption, the plurality of stacked sheets comprising a bottom sheet positioned at a bottom of the multi-layered plate and adapted to contain a first content; a top sheet positioned above the bottom sheet and adapted to contain a second content; at least one sheet stacked in between the top sheet and the bottom sheet and adapted to contain additional content; and an adhesive applied to edges of (i) the bottom sheet, (ii) the top sheet, and (iii) the at least one sheet stacked in between the top sheet and the bottom sheet except to at least one non-adhesive edge of (i) the bottom sheet and (ii) the at least one sheet stacked in between the top sheet and the bottom sheet, wherein the at least one non-adhesive edge of a sheet below the top sheet enables the top sheet to be peeled off, and wherein when the top sheet is peeled off from the sheet below the top sheet, an upper surface of the sheet below the top sheet is exposed. The bottom sheet comprises an upper surface and a lower surface that may be coated with a coatable substance, and the thickness of the bottom sheet may be greater than the thickness of the top sheet. The top sheet and the at least one sheet stacked in between the top sheet and the bottom sheet comprises an upper surface that may be coated with a coatable substance, and the thickness of the at least one sheet stacked in between the top sheet and the bottom sheet may be equal to the thickness of the top sheet.

Another aspect of the embodiments herein provides a method of manufacturing a multi-layered container for containing content, the method comprising arranging a plurality of sheets in a stack, wherein the plurality of sheets comprises a top sheet, a bottom sheet, and at least one sheet stacked in between the top sheet and the bottom sheet; pressing the top sheet, the bottom sheet, and the at least one sheet stacked in between the top sheet and the bottom sheet together into a mold to form the multi-layered container; and applying an adhesive to edges of (i) the bottom sheet, (ii) the top sheet, and (iii) the at least one sheet stacked in between the top sheet and the bottom sheet except to at least one non-adhesive edge of (i) the bottom sheet and (ii) the at least one sheet stacked in between the top sheet and the bottom sheet.

The at least one non-adhesive edge of a sheet below the top sheet enables the top sheet to be peeled off when a second content is consumed, wherein when the top sheet is peeled off from a sheet below the top sheet, an upper surface of the sheet below the top sheet is exposed for a first content to be placed thereon. The method may further comprise coating an upper surface of the top sheet, the bottom sheet, and the at least one sheet stacked in between the top sheet and the bottom sheet with a coatable substance. The method may further comprise coating a lower surface of the bottom sheet with the coatable substance. The thickness of the bottom sheet may be greater than the thickness of the top sheet. The thickness of the at least one sheet stacked in between the top sheet and the bottom sheet may be equal to the thickness of the top sheet. The top sheet, the bottom sheet, and the at least one sheet stacked in between the top sheet and the bottom sheet may comprise any of biodegradable and compostable materials. The multi-layered container may comprise any of a plate, a bowl, a platter, and a tumbler. The multi-layered container may comprise tableware. The multi-layered container may comprise cookware.

These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:

FIGS. 1A through 1E illustrate various views of a multi-layered container according to an embodiment herein;

FIG. 2 illustrates a close up view of the multi layered container of FIGS. 1 a through 1E illustrating a stack of sheets before they are pressed, with each sheet having a non-adhesive edge that allows it to be peeled off according to an embodiment herein;

FIG. 3 is a perspective view of a multi-layered plate that illustrates a top sheet being peeled off according to an embodiment herein; and

FIG. 4 is a flow diagram illustrating a method of manufacturing the multi-layered container of FIGS. 1A through 3 according to an embodiment herein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

As mentioned, there remains a need for a disposable plate or container that can be reused several times without wasting water, using dish soap, or filling up landfills. The embodiments herein provide a multi-layered plate or container that includes a plurality of sheets. The descriptions below refer to a first sheet and a second sheet. The second sheet is stacked above the first sheet. However, the plate may be configured with any number of stacked sheets. The first sheet and the second sheet are sealed together using an adhesive and pressed together to provide a shape and structure to the multi-layered plate. The second sheet includes a non-adhesive portion that enables the second sheet to be peeled off when content is consumed, and/or the second sheet is spoiled, exposing a clean or unused upper surface of the first sheet for containing another content for consumption. Referring now to the drawings, and more particularly to FIGS. 1A through 4, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.

FIGS. 1A through 1E illustrate various views of a multi-layered container 102 according to an embodiment herein. The multi-layered container 102 includes a first sheet 104 (e.g., a thick sheet) for containing a first content and a second sheet 106 (e.g., a thin sheet) for containing a second content. It is to be understood that the second content is actually placed/stored on the container 102 prior to the first content since the second sheet 106 is the top most layer on the container 102. The first sheet 104 is the bottom most layer on the container 102, and the second sheet 106 is above the first sheet 104. The second sheet 106 includes an upper surface 103 that is configured to be soak proof and cut resistant, and which may be coated with a coatable substance (e.g., a wax, etc.) (not shown in the drawings). The first sheet 104 may include a non-adhesive portion 108 that enables the second sheet 106 to be easily peeled off when the second content 105 (as shown in FIG. 3) is consumed. Again, the multi-layered container 102 may include more than one thin sheet (e.g., second sheet 106) in its stacked configuration that may be soak proof and cut resistant. The thin sheets (e.g., second sheet 106) may have a non-adhesive portion 108 (as shown in FIG. 2) that enables easy and convenient peeling off from the underlying sheet(s). The thickness of the thin sheet (e.g., second sheet 106) ranges from approximately 0.092 mm to 0.120 mm, in one example embodiment.

The first sheet 104 includes an upper surface 117 (as shown in FIG. 3) and a lower surface (not shown in the drawings) and is configured to be soak proof and cut resistant, and which may be coated with the coatable substance (e.g., wax, etc.) (not shown in the drawings). The multi-layered container 102 may include more than one thick sheet 104. The thickness of the thick sheet 104 (e.g., the first sheet) ranges from approximately 0.2 0mm to 1 mm, in one example embodiment. The first content 113 (as shown in FIG. 3) and the second content 105 (as shown in FIG. 3) may be food items, such as different courses of a meal, in one example embodiment, or may be any other type of content (edible or non-edible) for which plates are used for holding thereon. The first sheet 104 and the second sheet 106 may be steam pressed together into a mold (not shown in the drawings) to form the multi-layered container 102. The multi-layered container 102 may be configured as any of a plate, a bowl, a platter, a tumbler, tableware, cookware, etc., in example embodiments.

An adhesive (e.g., a natural adhesive, etc.) (not shown in the drawings) is applied to the edges of the first sheet 104 and the second sheet 106 except to at least one non-adhesive edge 108 of the first sheet 104. The non-adhesive edge 108 of the first sheet enables the second sheet 106 to be peeled off, and when the second sheet 106 is peeled off from the first sheet, an upper surface 117 (as shown in FIG. 3) of the first sheet 104 is exposed for the first content 113 (as shown in FIG. 3) to be placed thereon. The first sheet 104 and the second sheet 106 are steam pressed together at a predefined temperature suitable for retaining the first sheet 104 and second sheet 106 together prior to being peeled off from each other. In one example embodiment, the thickness of the first sheet 104 is greater than the thickness of the second sheet 106. In one embodiment, as shown in FIG. 1E, the multi-layered container 102 may include a third sheet 110 that is stacked above the second sheet 106. An upper surface 111 of the third sheet 110 is configured to be soak proof and cut resistant, and which may be coated with the coatable substance (e.g., wax, etc.) (not shown in the drawings).

The thickness of the third sheet 110 may be equal to the thickness of the second sheet 106. In one embodiment, the first sheet 104, the second sheet 106, and the third sheet 110 may include any of biodegradable and compostable materials. In another embodiment, the first sheet 104, second sheet 106, and third sheet 110 may have the same thickness. The size/dimension of the multi-layered container 102 may be any suitable size/configuration/shape, etc. In one example embodiment, the size of the multi-layered container 102 is approximately 27 cm in width, 27 cm in length, and 1.5 cm in height. However, the size/dimensions, and the shape may vary based on the requirement and/or the purpose. For example, the multi-layered container 102 may be manufactured in any shape such as circular, rectangular, square, oval, etc. and have any appropriate length, width, and height. In one example embodiment, in which the multi-layered container 102 is circular, the edge of the container 102 may be located anywhere in the periphery or the circumference of the container 102. The multi-layered container 102 may be microwavable, and/or freezable, in one example embodiment.

FIG. 2, with reference to FIGS. 1A through 1E, is a close up view of the multi layered container 102 illustrating a stack 200 of sheets 107 before they are pressed, with each sheet (e.g., the first sheet 104) having a non-adhesive edge 108 that allows the respective sheet (e.g., the second sheet 106) to be peeled off according to the embodiments herein. The close up view of the multi layered container 102 illustrates the stack 200 of sheets 107 (e.g., the first sheet 104, and the second sheet 106) with each sheet having one or more adhesive portions 109 adjacent to the one or more non-adhesive edges 108. Each sheet (e.g., the first sheet 104) having the non-adhesive edge 108 allows a respective sheet (e.g., the second sheet 106) to be peeled off once used (and/or spoilt). The second sheet 106 may include the non-adhesive edge 108, in one example embodiment. The non-adhesive edge 108 (i) enables peeling off the second sheet 106 when the second content 105 (as shown in FIG. 3) is consumed, and (ii) exposes the clean/unused upper surface 117 (as shown in FIG. 3) of the first sheet 104 for containing the first content 113 (as shown in FIG. 3) for consumption when the second sheet 106 is peeled off.

In one example embodiment, the multi-layered container 102 includes a third sheet 110 that is stacked above the second sheet 106. The third sheet 110 may include the non-adhesive edge 108 that enables (i) peeling off the third sheet 110 when a third content (not shown) is consumed, and (ii) exposes the upper surface 103 of the second sheet 106 for containing the second content 105 (as shown in FIG. 3) for consumption when the third sheet 110 is peeled off. Similarly, additional layers of sheets 115 can be added. In one example embodiment, the stack 200 of sheets 107 may include at least ten sheets, with the bottom most sheet (e.g., the first sheet 104) being the thickest.

FIG. 3, with reference to FIG. 1A through 2, is a perspective view of the multi-layered container 102 of FIG. 1 that illustrates a top sheet (e.g., the second sheet 106) being peeled off according to an embodiment herein. The multi-layered container 102 includes one or more sheets (e.g., the first sheet 104 and the second sheet 106). The top sheet (e.g., the second sheet 106) is peeled off from the multi-layered container 102 when the second content 105 is consumed, and exposes the upper surface 117 of the first sheet 104 for containing the first content 113 for consumption. After the second sheet 106 is peeled off, it can be discarded and the container 102 can continue to be used with the first sheet 104 containing the new content (e.g., first content 113) for consumption.

FIG. 4, with reference to FIGS. 1A to 3, is a flow diagram illustrating a method of manufacturing the multi-layered container 102 according to an embodiment herein. At step 402, two or more sheets (e.g., the stack 200 of sheets 107) are arranged in a stack 200. The two or more sheets 107 include a top sheet (e.g., the second sheet 106), a bottom sheet (e.g., the first sheet 104) and at least one sheet 115 stacked in between the top sheet 106 and the bottom sheet 104. At step 404, the upper surface of the two or more sheets 107 is configured to be soak proof and cut resistant, and which may be coated using a coatable substance (e.g., wax, etc.). At step 406, a lower surface of the bottom sheet 104 is configured to be soak proof and cut resistant, and which may be coated using the coatable substance (e.g., wax, etc.).

At step 408, the top sheet 106, the bottom sheet 104, and the at least one sheet 115 stacked in between the top sheet 106 and the bottom sheet 104 are pressed together into a mold to form the multi-layered container 102. At step 410, an adhesive is applied to edges of (i) the bottom sheet 104, (ii) the top sheet 106, and (iii) the at least one sheet 115 stacked in between the top sheet 106 and the bottom sheet 104 except to at least one non-adhesive edge 108 of (i) the bottom sheet 104 and (ii) the at least one sheet 115 stacked in between the top sheet 106 and the bottom sheet 104. A non-adhesive edge 108 of the at least one sheet 115 below the top sheet 106 enables the top sheet 106 to be peeled off when a second content 105 is consumed, and when the top sheet 106 is peeled off from the sheet 115 below the top sheet 106, an upper surface of the sheet 115 below the top sheet 106 is exposed for a next content (e.g., first content 113) to be placed thereon.

In one embodiment, the thickness of the bottom sheet 104 may be greater than the thickness of the top sheet 106. In one embodiment, the thickness of the least one sheet 115 stacked in between the top sheet 106 and the bottom sheet 104 may be equal to the thickness of the top sheet 106. In one embodiment, the top sheet 106, the bottom sheet 104, and the at least one sheet 115 stacked in between the top sheet 106 and the bottom sheet 104 may include any of biodegradable and compostable materials.

The multi-layered container 102 includes a plurality of sheets 107 including a first sheet 104 and a second sheet 106. The first sheet 104 is stacked below the second sheet 106 to provide strength to the multi-layered container 102. The edges of the first sheet 104 are applied with an adhesive except to at least one non-adhesive edge 108 of the first sheet 104.

The first sheet 104 and the second sheet 106 may be steam pressed together at a predefined temperature to provide a shape and structure to the multi-layered container 102.

The first sheet 104 may include a non-adhesive edge 108 that enables the second sheet 106 to peel off when a second content 105 is consumed. This exposes the upper surface 117 of the first sheet 104 for containing a next content (e.g., first content 113) for consumption. The second sheet 106 may include a non-adhesive edge 108. In one embodiment, the thickness of the first sheet 104 may be greater than the thickness of the second sheet 106. The multi-layered container 102 may include more sheets 115 that are stacked in between the first sheet 104 and the second sheet 106. A third sheet 110 may be positioned on top of the second sheet 106 and the thickness of the third sheet 110 may be equal to the thickness of the second sheet 106.

The embodiments herein provide a multi-layered container 102 that includes one or more sheets 107 that can be peeled off once used and provide another underlying sheet for containing a new content for consumption. The multi-layered container 102 is easy to use, and may be reused several times until the first sheet 104 in the stack 200 of sheets 107 is used, without wasting water or using dish soap. The multi-layered container 102 is compact to hold, store, ship, as well as for transport and may be used multiple times, thereby preventing overflowing of bins with bulk containers (e.g., bulk paper plates, etc.). The multi-layered container 102 is portable, disposable, and available at an affordable cost. The multi-layered container 102 is also stackable so that multiple containers 102 can be stored together (as indicated in FIG. 1C).

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims. 

What is claimed is:
 1. A multi-layered container for containing content adapted to be consumed, said multi-layered container comprising: a first sheet positioned at a bottom of said multi-layered container and adapted to contain a first content; a second sheet stacked on top of said first sheet and adapted to contain a second content; and an adhesive that is applied to edges of said first sheet except to at least one non-adhesive edge of said first sheet, wherein said at least one non-adhesive edge of said first sheet enables said second sheet to be peeled off, and wherein when said second sheet is peeled off from said first sheet, an upper surface of said first sheet is exposed for said first content to be placed thereon.
 2. The multi-layered container of claim 1, wherein a thickness of said first sheet is greater than a thickness of said second sheet.
 3. The multi-layered container of claim 1, further comprising a third sheet that is stacked above said second sheet.
 4. The multi-layered container of claim 3, wherein a thickness of said third sheet is equal to said thickness of said second sheet.
 5. The multi-layered container of claim 3, wherein upper surfaces of said first sheet, said second sheet, and said third sheet are coated with a coatable substance.
 6. The multi-layered container of claim 5, wherein a lower surface of said first sheet is coated with said coatable substance.
 7. The multi-layered container of claim 3, wherein said first sheet, said second sheet, and said third sheet comprise any of biodegradable and compostable materials.
 8. A multi-layered plate comprising a plurality of stacked sheets for containing content for consumption, said plurality of stacked sheets comprising: a bottom sheet positioned at a bottom of said multi-layered plate and adapted to contain a first content; a top sheet positioned above said bottom sheet and adapted to contain a second content; at least one sheet stacked in between said top sheet and said bottom sheet and adapted to contain additional content; and an adhesive applied to edges of (i) said bottom sheet, (ii) said top sheet, and (iii) said at least one sheet stacked in between said top sheet and said bottom sheet except to at least one non-adhesive edge of (i) said bottom sheet and (ii) said at least one sheet stacked in between said top sheet and said bottom sheet, wherein said at least one non-adhesive edge of a sheet below said top sheet enables said top sheet to be peeled off, and wherein when said top sheet is peeled off from said sheet below said top sheet, an upper surface of said sheet below said top sheet is exposed.
 9. The multi-layered plate of claim 8, wherein said bottom sheet comprises an upper surface and a lower surface that are coated with a coatable substance, and wherein a thickness of said bottom sheet is greater than a thickness of said top sheet.
 10. The multi-layered plate of claim 8, wherein said top sheet and said at least one sheet stacked in between said top sheet and said bottom sheet comprises an upper surface that is coated with a coatable substance, and wherein a thickness of said at least one sheet stacked in between said top sheet and said bottom sheet is equal to said thickness of said top sheet.
 11. A method of manufacturing a multi-layered container for containing content, said method comprising: arranging a plurality of sheets in a stack, wherein said plurality of sheets comprises a top sheet, a bottom sheet, and at least one sheet stacked in between said top sheet and said bottom sheet; pressing said top sheet, said bottom sheet, and said at least one sheet stacked in between said top sheet and said bottom sheet together into a mold to form said multi-layered container; and applying an adhesive to edges of (i) said bottom sheet, (ii) said top sheet, and (iii) said at least one sheet stacked in between said top sheet and said bottom sheet except to at least one non-adhesive edge of (i) said bottom sheet and (ii) said at least one sheet stacked in between said top sheet and said bottom sheet.
 12. The method of claim 11, wherein said at least one non-adhesive edge of a sheet below said top sheet enables said top sheet to be peeled off when a second content is consumed, and wherein when said top sheet is peeled off from a sheet below said top sheet, an upper surface of said sheet below said top sheet is exposed for a first content to be placed thereon.
 13. The method of claim 11, further comprising coating an upper surface of said top sheet, said bottom sheet, and said at least one sheet stacked in between said top sheet and said bottom sheet with a coatable substance.
 14. The method of claim 11, further comprising coating a lower surface of said bottom sheet with said coatable substance.
 15. The method of claim 11, wherein a thickness of said bottom sheet is greater than a thickness of said top sheet.
 16. The method of claim 11, wherein a thickness of said at least one sheet stacked in between said top sheet and said bottom sheet is equal to said thickness of said top sheet.
 17. The method of claim 11, wherein said top sheet, said bottom sheet, and said at least one sheet stacked in between said top sheet and said bottom sheet comprise any of biodegradable and compostable materials.
 18. The method of claim 11, wherein said multi-layered container comprises any of a plate, a bowl, a platter, and a tumbler.
 19. The method of claim 11, wherein said multi-layered container comprises tableware.
 20. The method of claim 11, wherein said multi-layered container comprises cookware. 